Co2 emission-free construction material made of co2

ABSTRACT

Building materials and methods of making a building material are disclosed. An exemplary method includes receiving algae; and subjecting the algae to an oil extraction process, in order to produce vegetable oil. The method further includes producing synthetic fibers by processing the vegetable oil from the oil extraction process; and processing the synthetic fibers to produce a tension and pressure resistant material.

This Application is a continuation-in-part of International PatentApplication PCT/EP2009/008497 of KUSE, Kolja filed 27 Nov. 2009 (U.S.National Phase Ser. No. 13/143,193), for CO2 EMISSION-FREE CONSTRUCTIONMATERIAL MADE OF CO2, the contents of which are herein incorporated byreference; which claims priority to 20 2008 015 775.7 filed 27 Nov.2008, the contents of which are herein incorporated by reference.

The present invention relates to a production practice of CO₂-emissionsneutral, or CO₂-emissions-free respectively, building materials. In asecond step CO₂ shall be even removed from the atmosphere by the processof energy production being necessary for the production of the buildingmaterial and permanently be bound in the building materials.

The process is being described based on a new, previously unknownmaterial flow. In front of the background of nowadays not disclaimedhappening global warming, it is important to optimize in particularthose processes which require a lot of production energy. A significantenergy sink is the production of materials having high pressure andtensile strength at the same time such as concrete, steel reinforcedconcrete, steel, glass and aluminum.

Without these materials, industrial manufacturing of necessaryfacilities and consumer goods of a modern living standard, such asbuildings, vehicles and machinery are currently not imaginable.

The production of these materials, which are artificially created byman, needs indeed large amounts of energy, which currently can only beobtained by a sufficient extent of fossil burning.

Thereby large amounts of CO₂ are being released, accelerating the longterm climate change by heating up the atmosphere in such a way that theclimate system is threatening to generate intolerable living conditionson planet Earth or even turn around completely, in case theCO₂-emissions will not be slowed down and be permanently brought down toalmost zero, respectively—at a certain level of concentration of CO₂ inthe atmosphere—a reduction of CO₂ from the atmosphere is becomingnecessary in order to come close to the climate target for example to gonot beyond a warming limit of 2° C. by year 2100 and then, ideally, getback step by step down to preindustrial levels again.

Embodiments of the present invention therefore offer a procedure toproduce pressure and tension stable materials in a CO₂-neutral way, andif necessary to remove CO₂ continuously over long periods from theatmosphere again through their own production. Recently, we succeeded toseparate CO₂ from flue gas in fossil-fueled power plants. This CO₂ isbeing discharged for example into vessels with salt water, in whichalgae growth is being stimulated through photosynthesis.

The algae absorb the carbon very quickly, faster than plants growing inair, releasing precious oxygen. From the algae it is easily possible towin oil.

The essence of embodiments of the present invention is based on the ideato use that oil as raw material, in order to produce synthetic fibers.

These synthetic fibers may be of such nature that they are furtherprocessed inter alia into coal fibers or carbon fibers or aramid fibers.

The necessary energy for the CO₂-sequestration, the production of thefibers and the needed pressure-resistant material components, such asnatural stone and the other needed energies for the production of thealgae oil are being derived from conventional power plants burningfossil fuels and/or renewable fuels such as biodiesel and otherrenewable energy sources like solar, wind and hydroelectric powerstations, with a surplus of that energy contributing to other generallyneeded power supply.

The carbon, which did previously cause the CO₂-problem, is now tied intothe building material of carbon fiber or aramid fiber.

The CO₂-neutrally produced, tension stable carbon fibers and aramidfibers are able—in cooperation with pressure-resistant materials such asnatural stone—to replace the currently used tension and pressureresistant conventional building materials such as concrete, steel andaluminum.

By combining the fiber of high tensile strength with compressionresistant materials that nature provides in the form of natural stone,available in unlimited quantities without a lot of energy expenditure,the required amount of carbon fiber or aramid fiber is significantlyreduced.

The resulting building material is henceforward based only on theprimary materials of salt water, carbon and natural stone, the energysource for the production of the building materials in the medium termis based on fossil burning and the sun, and in the long-term renewableburning—such as biodiesel—and the sun (with the help of parabolic powerplants, for example), since in this way, in the very long-term undthrough the generated energy savings by replacement of steel, Aluminumand concrete by fiber reinforced natural stone, a state can be reached,where it will be possible in the long run to abandon primary energy fromfossil burning.

By the combustion of regenerative burning materials, CO₂ will be fed tothe growth of algae, which has been previously in the atmosphere andwhich now becomes—on the basis of the algae oil—carbon fiber, and thusis being derived into an essential part of building materials.

This process chain finally leads to reduction of CO₂ from theatmosphere, which is being sustainably removed from atmosphere, sincethe building material is a solid state body, that will not decompose inform of the carbon fiber, but remains permanently stable even afterdisposal due to its coal constituents.

In the end-stage of the process, the atmosphere will be withdrawn fromCO₂ by the energy generation using biodiesel power plants andcarbon-sequestration by just as much as necessary.

At the end of this possibly decades or even centuries-long lastingprocess, the energy sources driving this process chain can be replacedby clean renewable energy sources of solar energy using parabolic mirrortechnology.

Also the pyrolysis process necessary fort he carbon fiber production canbe supplied with the related necessary high temperatures to above 1400°C. by bundling of solar energy with help of parabolic mirror technology.In this way an industry can be built, that is based on CO₂-neutral oreven CO₂-negative balances, without any need to abandon the necessarybuilding and construction materials. The building material or a part ofit respectively originates from the carbon itself, acting harmful in theatmosphere, and will be bound permanently within the building material,which will be discarded permanently bound underground after use or isbeing recycled accordingly.

BRIEF DESCRIPTION OF THE DRAWINGS

References are made, in the following text, to the accompanyingdrawings, in which:

FIG. 1 is a procedural diagram; and

FIG. 2 is a cross section of a natural stone plate stabilized withsynthetic fibers.

One of the many possible implementations of the invention describes amaterial-chain or a substance chain circuit respectively with anarrangement of a conventional fossil burning (for example coal poweredplant) fired power plant (1), whose exhaust gas separator (2)sequestrates the CO₂ (3) and intakes it into a salt water tank (4), inwhich algae (6) grow with the help of sunlight (5), which are beingcollected. From the algae (6) vegetable oil (8) is being obtained inoil-presses (7), which is being processed at first in production plants(9) to become synthetic fibers and then with help of sunray-bundlingdriven pyrolysis being processed into carbon fibers (10).

Woven fiber mats (11) are being produced from the carbon fibers.

The energy for the pyrolysis process for the carbonation of the fibersis being provided by the sunlight (5) with the help of parabolic mirrortechnology. These carbon fibers or carbon fiber mats (11) are beingcombined with low energy winnable pressure-resistant materials such asnatural stone (12) to become hybrid building and construction materials.

The natural stone will be coated by the fibers with the help of epoxyresin, which is also being won from the algae oil, thus forming aCO₂-neutrally won building material, from which, for example, more powerplants (1), buildings and vehicles can be built. The energy being neededfor the cutting of the stone and the production processes of the fibersand resin will be provided by the power plant (1).

The conventional power plant (1) will be gradually replaced by powerplants that are fired with renewable plant-based fuels instead of fossilburnings, in order to win the CO₂ which is being bound within therenewably growing fuels from the atmosphere, by capturing the CO₂ beingbound in the renewable plant-fuels, in order to use it for theproduction of carbon fibers with help oft he algae growth. Hencevaluable high performance tension stable building material is beingderived from CO₂ previously bound within the atmosphere, whereas thecarbon is permanently bound within the building material.

FIG. 2 shows the cross section of a natural stone plate (2) beingstabilized with synthetic fibers (1), being produced on the basis ofalgae oil, for the construction of buildings, vehicles, ships and otherindustrial and consumer goods using stabilization methods of naturalstone by fibrous material, also known as “stone composite technology” orCFS “carbon fiber stone” respectively, when the stone is being coatedunder preload of the carbon fibers.

Embodiments of the invention include a method for CO₂-emissions neutral,in a second step associated with a CO₂ emissions negative balance,production of pressure- and tension-stable building materials.

By the process of energy production by burning of fossil or renewableburning materials, rapid growth of algae is being stimulated bysequestration of CO₂, in order to utilize algae oil for the productionof synthetic fibers, which are serving in particular for the productionof carbon fibers to be further processed in such a way, that they areable to replace—in combination with natural stone for example—suchCO₂—intensive building materials like concrete, steel, glass andaluminum.

The needed high temperatures for the production of carbon fibers will begenerated in a CO₂-neutral manner by help of bundling of sun rays withthe help of for example parabolic mirror technology.

This approach provides the fundamental basis for the formation of aninitially CO2-neutral, later in time CO₂-negative balance based furtherindustrial development, in order to get control on and reverse globalwarming on Earth step by step over time.

1-8. (canceled)
 9. A method comprising: receiving algae; subjecting thealgae to an oil extraction process, in order to produce vegetable oil;producing synthetic fibers by processing the vegetable oil from the oilextraction process; and processing the synthetic fibers to produce atension and pressure resistant material.
 10. A method according to claim9 further including the processing of synthetic fibers being able toserve as base material for the carbonization process by pyrolysis intocarbon fibers.
 11. A method according to claim 9 further includingprocessing of synthetic fibers into aramid fibers.
 12. A methodaccording to claim 10 further including the usage of focused sun raysfor generation of the needed high pyrolysis temperatures for theproduction of the carbon fibers by carbonization.
 13. A method accordingto claim 12 further including coating of a pressure resistant materialwith the carbon fibers, to bring the second material under preload. 14.A method according to claim 11 further including coating a pressureresistant material with the aramid fibers, to bring the second materialunder preload.
 15. A method according to claim 13, the second materialconsisting preferably from natural stone or cast stone or concrete. 16.A method according to claim 14, the second material consistingpreferably from natural stone or cast stone or concrete.
 17. A method inaccordance with claim 9 wherein the oil extraction process includessubjecting the algae to an oil press, in order to produce the vegetableoil.
 18. A method in accordance with claim 15, characterized in thatduring the production of the building materials more, or at least aneven amount of CO₂ will be bound from atmosphere through their relatedproduction processes, than being released by their production processesinto the atmosphere.
 19. A method in accordance with claim 16,characterized in that during the production of the building materialsmore, or at least an even amount of CO₂ will be bound from atmospherethrough their related production processes, than being released by theirproduction processes into the atmosphere.
 20. A method according toclaim 9 further including processing the synthetic fibers to producecarbon fibers or aramid fibers.
 21. A method according to claim 9further including processing the synthetic fibers to produce carbonfibers.
 22. A method according to claim 21 further including focusingsun rays in order to generate high pyrolysis temperatures, to producethe carbon fibers.
 23. A method according to claim 9 further includingcoating a second material with the synthetic fibers, to bring the secondmaterial under preload.
 24. A method according to claim 9 furtherincluding processing the synthetic fibers, to produce carbon fibers; andcoating a second material with the carbon fibers, to bring the secondmaterial under preload.
 25. A method according to claim 9 furtherincluding coating a second material with the synthetic fibers, to bringthe second material under preload, the second material including naturalstone or cast stone or concrete.
 26. A method according to claim 9further including processing the synthetic fibers, to produce carbonfibers; and coating a second material with the carbon fibers, to bringthe second material under preload, the second material including naturalstone or cast stone or concrete.
 27. A method in accordance with claim 9wherein the oil extraction process includes subjecting the algae to anoil press, in order to produce the vegetable oil.